Auxiliary Air Suspension Installation Manual (RWD Single Tire) Iveco Daily L and S (2005) November 2018
CONTENTS 1. FOREWORD... 3 2. INTRODUCTION... 4 3. VERY IMPORTANT NOTES... 5 4. INSTRUCTIONS FOR INSTALLATION... 6 4.1. Recommended Tightening Torque... 6 4.2. Preparation... 6 4.3. Attachment of the Upper Brackets... 7 4.4. Attachment of the Left-side Lower Bracket... 7 4.5. Attachment of the Right-side Lower Bracket... 7 4.6. Attachment of Bellow... 8 4.7. Load Sensing Valve Adjustment (Models without ABS Only)... 8 4.8. Fitting of Inflator Console... 9 4.9. Tube Connection and Disconnection, Cutting and Routing... 11 4.10. Spring Inflation... 12 4.11. Spring Alignment... 13 4.12. Maintenance... 13 4.13. Check List... 14 5. INSTALLATION PHOTOS... 15 6. EPILOGUE... 20 DSC Nederland B.V. Het Wegdam 22 7496 CA Hengevelde Nederland Tel. : +31 (0)547 333065 Fax. : +31 (0)547 333068 e-mail: info@dunlopsystems.nl Website: 2017, DSC Nederland B.V. 2
1. FOREWORD This manual provides instructions for the installation of an auxiliary air suspension kit, developed specifically for the Iveco Single Rear Wheel Drive (2005). To ensure correct installation of the kit, it is strongly recommend that these instructions are read thoroughly before commencing any installation work. Installation should only be carried out by a suitably qualified mechanic or specialist installation facility. DSC Nederland will not accept any responsibility for faults or defects arising from incorrect installation, which automatically renders the guarantee invalid. IMPORTANT : Manufacturer s Declaration Form A manufacturer s declaration form is provided with your kit. Following installation of the kit please ensure that this form is completed, signed by a qualified fitter and a copy is returned to DSC Nederland by post, fax or e-mail. Our e-mail address is: info@dunlopsystems.nl 3
2. INTRODUCTION Thank you for choosing an auxiliary air suspension kit from the range offered by DSC Nederland Auxiliary air suspension is fitted in tandem with the standard steel springs of the vehicle suspension, and provides enhancements in terms of both the stability of the vehicle and the comfort of the passengers Vehicle Levelling Simply by varying the air pressure in the springs, the vehicle can be levelled both front-to-rear and side-to-side. Keeping the vehicle level optimises stability, ensures correct headlamp beam distribution and reduces tyre wear arising from uneven distribution of weight. Straight Line Stability Straight line stability is greatly increased at higher speeds, and when subjected to buffeting from cross-winds or large overtaking vehicles. Reduced Body Roll Body roll when cornering or negotiating roundabouts is significantly reduced. Fatigue Reduction and Wear Compensation Suspension fatigue is reduced, so helping to prevent leaf springs from sagging under repeated or constant loading. Any sagging already present can be compensated-for. This is a particular benefit for motorhomes, which are always fully laden. Ride Comfort Air springs help to absorb shock loads from uneven road surfaces, therefore general ride quality is much improved. 4
3. VERY IMPORTANT NOTES Gross Vehicle Weight (GVW) Air assist kits are not in themselves designed to increase the gross vehicle weight (GVW) rating of a vehicle. They do not legally allow for carriage of a load greater than the carrying capacity stated on the data plate of the vehicle. Do not exceed the maximum load specified by the vehicle manufacturer to avoid compromising passenger safety to prevent possible damage to the vehicle for legal reasons Vehicle Uprating Despite the above words of caution, it is possible to upgrade the weight rating of your vehicle. This must be carried-out by a specialist supplier that will carry out any necessary modifications in addition to fitting the air assist kit complete documentation as necessary to inform the Vehicle and Operator Services Agency (VOSA) a mandatory requirement supply and fit a new weight plate to replace the original plate supplied with the vehicle This process applies to United Kingdom registered vehicles. The process in other countries may be different. This process applies to United Kingdom registered vehicles. The process in other countries may be different. Safety Guidance Note The following very useful guidance note is available for free download from the Health and Safety Executive (HSE) PM85, July 2007 Safe recovery (and repair) of buses and coaches fitted with air suspension The uniform resource locator (URL) for this document is http://www.hse.gov.uk/pubns/pm85.pdf 5
4. INSTRUCTIONS FOR INSTALLATION Preparation and Precaution Before beginning installation, ensure that you have sufficient clearance between the axle and the chassis. Use a jack if necessary. Install at one side of the vehicle at a time. Pay attention to your safety at all times during installation - always use axle stands to support the vehicle! The position of the axle stands should be under the chassis NOT under the axle! 4.1 Recommended Tightening Torque During fitting of the air suspension system, it is recommended that nuts and bolts are tightened in accordance with the following table... METRIC TORQUE CHART IN N.m SIZE CLASS 8.8 CLASS 10.9 M6 x 1 9.9 14.0 M8 x 1.25 24.0 34.0 M10 x 1.5 48.0 67.0 M12 x 1.75 83.0 117.0 M16 x 2 200.0 285.0 When both the bolt and nut are made from steel use either class 8.8 or 10.9 For all other materials, tightening torque is left to the discretion of a person skilled in the art The following instructions make reference to the diagrams on pages 15 to 19 inclusive. 4.2 Preparation i. Secure the front wheels, use wheel chocks on both sides of both front wheels. i. Take the ground terminal from the battery when work to electricity is involved. ii. Lift the rear of the vehicle till there is working space of approximately 25 cm between bump stop and rear axle. 6
4.3 Attachment of the Upper Brackets i. Unscrew and temporarily remove the bump stop housing bracket Figures 1 and 2 ii. iii. Offer the upper bracket up to the chassis rail at the site where the bump stop bracket is normally attached - Figure 3 - then reattach the bump stop bracket thereby securing the upper bracket to the chassis - Figures 4 and 5 Once both upper brackets are in place, attach the cross member between them - Figures 6 and 7 4.4 Attachment of the Left-side Lower Bracket i. Unscrew the axle vent tube from the axle and in its place fit the extension tube supplied - Figures 8 to 11 ii. Attach the axle vent tube to the extension tube - Figures 12 and 13 iii. Place the lower-left bracket onto the axle such that the two vertical slots mate with the large U-bolts that attach the leaf spring to the axle and the large slot in the bracket rests over the vent tube extension at the position at which it is attached to the axle - Figures 14 and 15 4.5 Attachment of the Right-side Lower Bracket i. Place the lower-right bracket onto the axle such that the two vertical slots mate with the large U-bolts that attach the leaf spring to the axle - Figure 17 ii. Secure the lower bracket to the axle via a U-bolt - Figure 18 7
4.6 Attachment of Bellow Iveco Daily L and S i. Connect a tube to each bellow - refer to section 4.7 Compress each bellow and then bung the attached tube to maintain the state of compression ii. iii. iv. Feed the tube through the slot in the upper bracket and place the air spring between the upper and the lower brackets - Figure 19 Remove the bung and the spring will inflate until its upper and lower plates are in contact with the upper and lower mounting brackets respectively Attach the air spring to the upper and lower mounting brackets using 4-off M8 x 16mm bolts and spring washers - Figures 20 and 21. Do not fully tighten the bolts as yet. 4.7 Load Sensing Valve Adjustment (Models without ABS Only) Vehicles not fitted with an antilock braking system will have a load sensing valve (LSV). This valve must be adjusted prior to operating a vehicle fitted with an air assist kit. i. Unscrew and remove the load sensing valve lever and connecting rod, indicated by the arrows in Figure 22 ii. iii. See Figure 23. Attach the boomerang -shaped bracket supplied, via its through-bolt, to the bracket hanging from the chassis as vacated by removal of the lever in the previous step. Attach the hook at the end of the coil spring linkage through the hole in one arm of the boomerang. Tension the coil spring linkage as follows See Figure 24. Loosen the nut indicated by the arrow on the left and then hang a weight from the hole indicated by the arrow on the right Daily L 8.75kg Daily s 12.25kg Whilst this weight is hanging re-tighten the nut and finally remove the weight. 8
4.8 Fitting of Inflator Console Iveco Daily L and S OPTION VALVES OPTION 1 OPTION 2 OPTION 3 Your kit is supplied with one of the inflator options shown above OPTION VALVES : Two valves and a small bracket OPTION 1 : Two valves in a console with two independent 10-bar pressure gauges OPTION 2 : Two valves in a console with two independent 10-bar pressure gauges and a rocker on/off switch to operate the electric motor driven air compressor OPTION 3 : Four valves (two for raising the vehicle ( UP ) and two for lowering the vehicle ( DOWN )) in a console with two independent 10-bar pressure gauges. A pressure switch operates the electric motor driven air compressor to keep the air reservoir of 1.9-litre at pressure. 9
Mount the console in a position of your choice whereby it is firmly fixed, has some protection from the environment (particularly important for the console with gauges) and is easily accessible. Suggested possible locations include... Standard Console on the rear bumper at the rear beside the license plate on the chassis next to a rear wheel in a service shutter (motorhomes) beside the fuel cap Option 1, Option 2 or Option 3 Console in the vehicle cabin, within reach and sight of the driver Beside, under the driver seat in the wall of a cupboard (motorhomes) in a service shutter (motorhomes) Comfort Packages The Option 2 and Option 3 panels, as shown above, are each part of a Comfort Package that is supplied with a compressor (and also an air reservoir in the case of the Option 3 panel) for ease of spring inflation and ride height setting. For further information please ask your dealer. The picture below shows all of the parts of Comfort Package Option 2... Comfort Package Option 2 10
4.9 Tube Connection and Disconnection, Cutting and Routing Connection and Disconnection Tubes are connected as shown by the diagrams below... A B C A. Slide a nut over the end of the tube B. Push the tube onto the connector as far as possible C. Feed the nut up to the connector, fully tighten by hand and finally tighten one additional turn using spanners Cutting To achieve good sealing and air-tight fitting of tube ends to their connecting parts, it is very important to cut tubing cleanly and squarely. A dedicated guillotine action tubing cutter is recommended, or a craft knife if such a tool is not available. Do not use electrician s side cutters. A dedicated tubing cutter - Recommended Electrician s Side Cutters NOT Recommended 11
Routing Study the underside of the vehicle and decide how to route each branch of the air circuit To minimise the risk of chafing, avoid running tubing over metal edges as much as possible Avoid close proximity to heat sources such as the exhaust assembly Choose a route that provides as much protection as possible from dirt, debris and any solid objects that may impact the underside of the vehicle It is recommended that tubes are guided alongside brake lines as much as possible. Use cable ties ( tie wraps ) to secure tubing to the chassis, taking care not to over-tighten them. 4.10 Spring Inflation Once installation of the air assist kit is complete, inflate the springs to achieve the desired ride height via the inflator console taking careful note of the following... Maximum and Minimum Pressure Maximum Pressure 7.0bar Minimum Pressure 0.5bar Do not exceed 7.0bar (101psi), which is the recommended maximum charge pressure for the air springs. The springs may be deflated if the vehicle is to be stored for a lengthy period without use, but a pressure of at least 0.5bar (7.25psi) should be maintained at all times in order to avoid possible compression damage to the springs. With the vehicle standing at the desired ride height, it is recommended that the height of the bellow itself should be between 18cm and 22cm. 12
4.11 Spring Alignment Iveco Daily L and S Spring out of alignment mounting plate axes offset Spring in alignment mounting plates parallel and coaxial CAUTION! Before fully tightening the bolts that secure the air spring to the upper and lower brackets, set the vehicle at ride height (spring height approximately 13.5cm) and ensure that the springs are correctly aligned. 4.12 Maintenance Following installation, it is recommended that all metal parts are coated with a protective substance such as body wax. The system does not require very much maintenance other than to maintain air pressure in the springs. Much like a tyre, the system may lose a little air over time. to keep the air bellows clean. It is suggested that, when washing the vehicle, the bellows are inspected and cleaned as necessary (preferable by spraying). Look in particular for stones or grit trapped between convolutes, as this may damage the bellow. Check before and after the winter period the wax coating. Re-wax when necessarily 13
2 Iveco Daily L and S 4.13 Check List Before driving the vehicle following completion of installation of the auxiliary air suspension system, please check......all bolts tightened to the recommended torque (Page 7)?...air springs set in alignment (Section 4.10)?...enough free space around the air springs to avoid wearing?...all metal parts wax coated (Section 4.11)?...manufacturer s declaration form completed and a copy returned? A wait of 24 hours is recommended in order to ensure that the vehicle has maintained its stance and that there are no air leaks present. 14
5. INSTALLATION PHOTOS 15
1 2 3 4 5 6 16
7 8 9 10 11 12 17
13 14 15 16 17 18 18
19 20 21 22 23 24 25 Spring out of alignment mounting plate axes offset Spring in alignment mounting plates parallel and coaxial 19
6. EPILOGUE DSC Nederland hopes that you enjoy the benefits that your DUNLOP air suspension system will provide for you. To ensure optimal performance, we advise that you have your system checked frequently by qualified personnel. As recommended in the fitting instructions, it is important to coat all the steel parts with a protective substance such as body wax. IMPORTANT : Manufacturer s Declaration Form A manufacturer s declaration form is provided with your kit. Following installation of the kit please ensure that this form is completed, signed by a qualified fitter and a copy is returned to DSC Nederland by post, fax or e-mail. Our e-mail address is: info@dunlopsystems.nl As a condition of your warranty, modifications to the system may only be carried out by personnel of DSC Nederland. Enquiries For general enquiries please contact one of our dealers. You can find them on our website. 20
Auxiliary Air Suspension DSC Nederland B.V. Het Wegdam 22 7496 CA Hengevelde Nederland Tel. : +31 (0)547 333065 Fax. : +31 (0)547 333068 e-mail: info@dunlopsystems.nl